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Sonics FM Instruction Manual

Sonics model fm power supply instruction manual
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Model FM Power Supply
I N S T R U C T I O N
M A N U A L
Sonics & Materials, Inc.

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  • Page 1 Model FM Power Supply I N S T R U C T I O N M A N U A L Sonics & Materials, Inc.
  • Page 2 (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax www.sonicsandmaterials.com • info@sonicsandmaterials.com europe@sonicsandmaterials.ch Information contained in this manual is subject to change without notice. Sonics & Materials, Inc. is not responsible for any typographic errors. © Sonics & Materials, Inc. 2001 Printed in U.S.A.

  • Page 3: Table Of Contents

    T A B L E O F C O N T E N T S IMPORTANT SERVICE LITERATURE ......4 Manual Change Information .
  • Page 4 ENERGY-BASED MODES ........23 Constant Energy-Based Cycle with Time Delay Triggering ..23 Constant Energy-Based Cycle with Variable Force Triggering .

  • Page 5: Important Service Literature

    I M P O R T A N T S E R V I C E L I T E R A T U R E The system supplied with this instruction manual is constructed of the finest material and the workmanship meets the highest manufacturing standards. It has been thoroughly tested and inspected before leaving the factory and when used in accordance with the procedures outlined in this manual, will provide you with many years of safe and dependable service.

  • Page 6: Unpacking And Inspection

    If the system or any unit is damaged, notify “Sonics.” “Sonics” will arrange for repair or replacement of damaged equipment without waiting for the claim against the carrier to be settled, provided a new purchase order is issued to cover the repair or replacement costs.

  • Page 7: Introduction

    I N T R O D U C T I O N The FM model power supply is an auto-tuned ultrasonic generator with a built- in Microprocessor that allows time and energy-based control. The Microprocessor is programmed with a multi-function keypad and information is displayed on the back-lit liquid crystal display (LCD).
  • Page 8 “SONICS” ULTRASONIC ASSEMBLY SYSTEMS 50/60 Hz Electrical power Power Supply/Generator Generates ultrasonic electrical energy (15/20/40 kHz) Ultrasonic electrical energy Actuator/Press Provides compressive force and mounting for Converter, Converter Booster, Horn assembly Transforms ultrasonic electrical energy to ultrasonic mechanical vibrations Ultrasonic Vibrations...

  • Page 9: Glossary Of Ultrasonic Terms

    G L O S S A R Y O F U L T R A S O N I C T E R M S POWER SUPPLY/GENERATOR – The solid state power supply converts standard 50/60 Hz electrical energy to 15,000 Hz, 20,000 Hz or 40,000 Hz (15/20/40 kHz) electrical energy.

  • Page 10: Installation

    I N S T A L L A T I O N ELECTRICAL POWER REQUIREMENTS The power supply requires a fused, single-phase, standard 3-terminal grounding type receptacle capable of supplying the requisite voltage and current. Refer to the table below for power specification. The line cord of the POWER SPECIFICATIONS controller/power supply is...

  • Page 11: Electrical Connections

    ELECTRICAL CONNECTIONS The standard cable supplied with a “Sonics” press is 10 feet. Optional extension cables are available up to 15 feet without modification. When making the initial electrical connections, make sure the power is disconnected and follow these precautions.

  • Page 12: Cable Connections

    CABLE CONNECTIONS: Located at the rear of the power supply are the cable connections as illustrated below. (The interconnecting cables will be supplied with your system.) 1. J1, a round, 12-pin RF cable that connects the welding press or converter NOTE: Detailed wiring to the power supply.

  • Page 13: Available Converters

    AVAILABLE CONVERTERS Item No. Description CV00015 20 kHz with Button connector CV00151 20 kHz with Lemo connector CV00154 20 kHz with Lemo connector and fitting for air cooling CV00157 20 kHz with Button connector and fitting for air cooling CV00158 20 kHz Hand Gun with handles and cables CV00331 20 kHz with Fischer connector...

  • Page 14: Operating Procedures

    O P E R A T I N G P R O C E D U R E S FRONT PANEL CONTROLS AND INDICATORS Located on the front panel of the power supply are the following controls and indicators: MICROSONIC PROCESSOR™ 80 100 TIMER +LIM...
  • Page 15 7. REF key which displays energy in Watt Seconds (Ws) when the constant energy mode has been selected, and permits adjustment of the set value in .1 Ws increments. Green LED in the upper left corner indicates completion of an acceptable process cycle. 8.

  • Page 16: Operational Signals

    Press the ON/OFF key to turn the power supply on. The red LED will light up indicating the unit is on. The LCD screen will briefly display “Sonics & Materials.” If a printer or CRT is not connected to the system, the following message will also be displayed...

  • Page 17: Initial Operation

    LCD reading. Make sure the reading on the LCD display (see example below) does not exceed 10%. US-TEST = 05% a) If the display is above 10%, contact Sonics immediately for further instructions before proceeding. b) If the display is below 10%, you can proceed with operation.

  • Page 18: Basic Modes Of Operation

    B A S I C M O D E S O F O P E R A T I O N The FM power supply’s built-in microprocesor allows the use of either time- based or energy-based cycles in four basic modes, as follows: 1.

  • Page 19: Mode Codes Display

    MODE CODES DISPLAY The power supply is shipped with blank programs, so all data and parameters must be input by the customer. On initial start-up, the default mode selected is the Time-Based cycle. Press the INFO key four times and the following “Mode Codes”...

  • Page 20: Time-Based Modes

    T I M E - B A S E D M O D E S SELECTING AND SETTING TIMERS IN A TIME-BASED CYCLE (with delay triggering) As described on the previous pages, the default mode is the Time-Based cycle. Pressing the INFO key four times would display the following codes on the LCD Screen: NOTE: When the Time- Based mode is in effect,...

  • Page 21: Selecting And Setting The Afterpulse Timer

    Pre-triggering is accomplished by setting T1 to 0.00 sec, thus continuing the calibration pulse until T2 is actuated by the horn contacting the workpiece. The Delay Timer (T1) can only be set or changed when Delay Timer Triggering (T1) has been selected. The Delay Timer is not operational when the Force Triggering function (FT) has been selected.

  • Page 22: Selecting And Setting Process Control Tolerance Limits In A Time-Based Cycle

    key to activate and cancel the Afterpulse function.) When the Afterpulse Timer is cancelled, the function letter “U” will no longer appear in the Mode Codes display. SELECTING AND SETTING PROCESS CONTROL TOLERANCE LIMITS IN A TIME-BASED CYCLE The process control tolerance limits are established in energy (Ws) when the Time-Based mode (ZT) is in effect.
  • Page 23 Press the ENTER key or any other key to enter the new Force Trigger set value, or wait 30 seconds for automatic acceptance. The Force Trigger (FT) value can only be set or changed when the Force Triggering (FT) mode is in effect. It is not operational when the Time Delay Triggering function (T1) has been selected.

  • Page 24: Energy-Based Modes

    E N E R G Y - B A S E D M O D E S CONSTANT ENERGY-BASED CYCLE WITH TIME DELAY TRIGGERING When the CONSTANT ENERGY function (EN) has been selected, the weld cycle follows the termination of a predetermined delay period (T1) and continues until a pre-selected amount of energy (Ws) has been delivered to the components being assembled.

  • Page 25: Constant Energy-Based Cycle With Variable Force Triggering

    That is, if the value set for the Abort timer (T5) is reached before the programmed energy value is met, sonics will be terminated and the hold cycle will be initiated.

  • Page 26: Overview Of Operations And Lcd Displays

    MICROSONIC PROCESSOR™ OPERATING INSTRUCTIONS DISPLAY KEY OPERATION DISPLAY FUNCTION BEFORE SEQUENCE AFTER START-UP Start power supply — SONICS AND MATERIALS and Microsonic •••• NO PRINTER •••• Processor™ READY TEST Test for idle losses in air READY TEST US - TEST = 5% TIMER...
  • Page 27 DISPLAY KEY OPERATION DISPLAY FUNCTION BEFORE SEQUENCE AFTER AFTERPULSE Select Afterpulse Timer (T4) or cancel Afterpulse T1 ZT NB IS 1 48 M FT ZT NB IS 1 48 M Timer (T4). TRIGGER FORCE Select Trigger Force READY TRIGGER (F) = 1% TRIGGER Set Trigger Force TRIGGER (F) = 1%...

  • Page 28: Overview Of Set-Up Procedures And Displays

    DISPLAY KEY OPERATION DISPLAY FUNCTION BEFORE SEQUENCE AFTER START-UP Start power supply — SONICS AND MATERIALS •••• NO PRINTER •••• READY TEST Test for idle losses in air READY US - TEST = 5% TEST FORCE TRIGGER Determine whether READY...
  • Page 29 DISPLAY KEY OPERATION DISPLAY FUNCTION BEFORE SEQUENCE AFTER UPPER LIMIT Select Upper Limit READY + LIM = 0.00 sec + LIM function Set Upper Limit + LIM = 0.00 sec + LIM = 0.90 sec ex: 0.90 sec. Enter set-value + LIM = 0.90 sec READY ENTER...

  • Page 30: Additional Features And Functions

    PROGRAM VERSION DESIGNATION To review the program version number, press and hold the TEST and REF keys simultaneously when “SONICS & MATERIALS” appears on the LCD DISPLAY at start-up. The display will then show the program version number i.e., V2.6 845-19 1500W. To return to system status READY, simply release the TEST and REF keys.
  • Page 31 J O B N U M B E R : _ _ Saved jobs will be numbered 1 through 9. Use the numerical keys to enter in the desired job number (1 - 9). Once the job number is keyed in, press the ENTER key.

  • Page 32: Job Sequence

    P R E S S U R E 0 . 0 0 P s i g Use the numerical keys to enter in the new pressure value. When the desired pressure is displayed on the LCD screen, press the ENTER key. The LCD screen display will show the following: B O O S T E R G A I N = 0 .

  • Page 33: Cal Pulse

    The following is an example where four jobs are to be sequenced and one set of parameters (Job 1) is to occur twice in the sequence. The sequence is as follows: S E Q U E N C E 1 2 1 5 The LCD screen will show the following displays as the jobs are sequenced: Display for first cycle...

  • Page 34: Keypad Security

    K E Y P A D S E C U R I T Y The keypad can be “locked” so that all operating parameters that are selected and set with the keypad are locked in, preventing unauthorized cancellation or adjustment. To activate the security feature, first press the INFO key 4 times to display the current Mode Codes (i.e., T1 ZT NB IS 1 48 M, or other variation).

  • Page 35: Printer Interface And Operation

    P R I N T E R I N T E R F A C E A N D O P E R A T I O N PRINTER OPERATION If a printer is to be used for documentation of the dynamic process conditions, it must have an RS232 serial port interface, a buffer of 2K bytes and be capable of accepting a transmission rate of 4800 Baud.

  • Page 36: Printer Displays

    PRINTER DISPLAYS Time Based mode with delay timer triggering Power Supply Mode Codes Program Version Output Rating SONICS AND MATERIALS V3.0 845-73 1500W T1 ZT NB IS 1 48 M Delay Timer Timer 1 = 0.25 sec Weld Timer Timer 2 = 0.15 sec...
  • Page 37 Constant energy mode with variable force triggering Power Supply Mode Codes Program Version Output Rating SONICS AND MATERIALS V3.0 845-73 1500W FT EN NB IS 1 48 M Trigger Force Trigger (F) = 2% Energy Set-Value REF = 91.0 Ws + LIM = 0.20 sec...

  • Page 38: Graph Header

    The keypad is not functional during the time a printout is being made until a short audible tone is heard and the LCD returns to system status “READY.” Printing can be stopped at any time by pressing any key. The printer will continue printing, however, until the data stored in the buffer has been printed.

  • Page 39: Reject Printouts

    REJECT PRINTOUTS The reason for a reject, such as ± LIM or T5, will be printed out for each weld. If the Timer 5 limit is exceeded, then the printout will read as follows: 25 76/o 176.6 ws 0.40 sec. **** Reject T5 For the example above, the printout indicates that this cycle was rejected because the Timer 5 setting (0.40 sec.) was exceeded.

  • Page 40: System Status Tests And Functions

    To display the status of the various system inputs, press the TEST and AUTO keys simultaneously when “SONICS & MATERIALS” appears on the LCD screen at start-up. The display will change to “INPUT TEST.” When the TEST and AUTO keys are released, the status of the various inputs will be displayed in an alphabetical code.

  • Page 41: Printer Test

    PRINTER TEST (only with Optional Peripherals) To access the Printer Test feature, first ensure that the optional printer is “ON.” Then, press the TEST and PRINT keys simultaneously when “SONICS AND MATERIALS” appears on the LCD screen at start-up. The display will change to “PRINTER TEST”...

  • Page 42: Coupling Force Measurement

    CLEAR PARAMETERS To cancel all variable parameters and release keypad security, press the INFO and F TRIGGER keys simultaneously when “SONICS & MATERIALS” appears on the LCD screen at start-up. The power supply will return to normal Force Trigger Operation with Delay Triggering mode.

  • Page 43: System Status Tests

    S Y S T E M S T A T U S T E S T S SYSTEM STATUS TESTS AND MISCELLANEOUS FUNCTIONS DISPLAY KEY OPERATION DISPLAY FUNCTION BEFORE SEQUENCE AFTER Input Test SONICS AND MATERIALS TEST INPUT TEST AUTO ABCDEFGhIJKLMNoP CRT Monitor/Printer SONICS AND MATERIALS INFO * * PRINTER TEST * * Test Cancel Parameters...

  • Page 44: Overload Protection

    OVERLOAD PROTECTION The overload protection circuit will terminate sonics when the system is operated under adverse conditions, i.e., improper tuning, excessive power supply loading, loose or failed horn or booster, thereby protecting the power supply and other system components. When an overload condition exists, the RESET button will illuminate and remain lit until the button is pressed (regardless of whether the condition is corrected or not).

  • Page 45: Maintenance

    M A I N T E N A N C E GENERAL 1. Always make sure the power supply has adequate ventilation by keeping sufficient space around the assembly. 2. Periodically check the ventilation grilles and clean as necessary. REPAIRS / SERVICE If problems are encountered, contact our Service Department at 1-800-745- 1105.

  • Page 46: Warranty

    No person or company is authorized to change, modify, or amend the terms of this warranty in any manner or fashion whatsoever. Under no circumstances shall “Sonics” be liable to the purchaser or to any other person for any incidental or consequential damages or loss of profit or product resulting from any malfunction or failure of this “Sonics”...

  • Page 47: Appendix

    A P P E N D I X DIP SWITCH DEFAULT SETTINGS SWITCH POS. OFF POS. ON DEFAULT DIP-1 Force Trigger Mode (FT) T1 (ZT) Model DIP-2 Weld by Timer 2 (T2) Weld by Energy (EN) DIP-3 Normal mode without Rotary table Rotary table mode to DIP-4 DIP-4 Rotary table mode with pulse control...
  • Page 48 E-2703 Impulse Actuation Cable E-2902 Good Part/Bad Part and Abort Cable. Special* E-2952 FM Wiring Diagram E-3013 F-Series General I/O E-3014 F-Series General I/O *Pin 3 has 24 vdc for the reject output and pin 2 has a switched return on standard machines. Good part/Bad part and Abort is a special modification.
  • Page 49 A P P E N D I X • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • I N S T R U C T I O N M A N U A L •...
  • Page 50 A P P E N D I X • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • I N S T R U C T I O N M A N U A L •...
  • Page 51 A P P E N D I X • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • I N S T R U C T I O N M A N U A L •...
  • Page 52 A P P E N D I X • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • I N S T R U C T I O N M A N U A L •...
  • Page 53 A P P E N D I X • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • I N S T R U C T I O N M A N U A L •...
  • Page 54 A P P E N D I X • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • I N S T R U C T I O N M A N U A L •...
  • Page 55 Sonics & Materials, Inc. Corporate Headquarters European Office 53 Church Hill Road • Newtown, CT 06470 USA 22 ch du Vernay • CH - 1196 Gland, Switzerland 203.270.4600 • 800.745.1105 • 203.270.4610 fax (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax www.sonicsandmaterials.com •...

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